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Spot Welding Guns 3321N

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1. POWER 1 9 N IMPULSE Ho copa H1 SLOPE DOWN H2 cops H8 POsrwELD PosrweELDNGTME o o L4 POSTPOWER POSTWELDINGCURRENT H5 He orrmwe 1 o 17 CURRMIN CURRENT MIN LIMIT ANGLE MIN MIN LIMIT IN DEGREES CURR MAX CURRENT MAX LIMIT ANGLE MAX MAX LIMIT IN DEGREES Obtained welding current in Ka _______ POSSIBLE STEPPER FUNCTION ADJUSTING PARAMETERS DELTA INCREMENT SPOTS COUNTER Enclose all other useful information for instance maintenance and electrodes replacement times notes on the pieces preparation etc EDITION MAY 2007 Page 57 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 This page intentionally left blank EDITION MAY 2007 Page 58 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 This page intentionally left blank EDITION MAY 2007 Page 59 60 LORS TECNA 1090 LOUSONS ROAD UNION NEW JERSEY 07083 USA Tel 908 964 9100 Fax 908 964 4492 email sales lors com
2. EDITION MAY 2007 Page 42 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 7 3 ELECTRODE FORCE ADJUSTMENT OPERATOR QUALIFICATION NUMBER OF OPERATORS SAFETY MEASURES WELDER STATUS o Q NO WELD The welding force must be selected taking into consideration both tables and personal experience and in relation to the sheets thickness the desired spot quality etc Always adjust by keeping the welding control unit on NO WELD in order to avoid any risk caused by a wrong adjustment Always carry out NO WELD cycle tests before starting the welding process An excessive electrodes force can cause e welding over marks possible electrodes short life e weak welding or false welding due to a reduction of the contact resistance which allows the current to pass through without bringing the piece to the melting temperature An insufficient force on electrodes can cause spatters of melted material e Stuck weld of the pieces on the electrode welding with a disagreeable outside surface If the welding to be carried out requires low or precise force values it is advisable to verify the adjusted force by means of a dynamometer The electrodes force adjustment is carried out by means of the pressure regulator placed on the welder supply The supply pressure variation displayed by the relevant pressure gauge modifies the welding force The reached force values concerning the different pressure values showed
3. essen EDITION MAY 2007 Page 3 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 This page intentionally left blank EDITION MAY 2007 Page 4 60 LCRS TECNA 0 INTRODUCTION CAREFULLY READ THIS INSTRUCTION MANUAL BEFORE INSTALLING AND OPERATING THE WELDER 0 1 PURPOSE OF THE INSTRUCTION MANUAL This instruction manual is part of the welder and is aimed at providing all the necessary information in order to Provide the operators with the proper information concerning safety issues e Handle the welder both packed and unpacked under safety conditions e Properly install the welder e Deeply be acquainted with the working of the welder and its limits Use properly the welder under safety conditions e Change type of production and perform maintenance adequately and safely Dismantle the welder under safe conditions and in compliance with the provisions in force about the workers and environment care A The personnel responsible of each department in which the welder will be installed are obliged according to the laws in force to carefully read the content of this document and make it available for reading to the personnel who use and maintain the welder for the parts relevant for them The time spent in this activity will be widely saved thanks to a proper working of the welder and its use under safety conditions This document is based on the supposition that the safety and
4. 2 1 DESCRIPTION OF THE WELDER MAIN AIR OPERATED PRODUCTION SPOT WELDING GUNS FEATURES WITH BUILT IN ELECTRONIC TIMER High productivity achieved with rational design reduced overall dimensions high welding capacity Reduced installation costs Gyro suspension on balls together with a spring balancer guarantees accurate maneuverability at any degree Rotation locking device Fully water cooled electrodes electrode holders arms and transformer Taps for the water cooling system make changes easy to be performed Adjustable electrode distance working stroke Adjustable short working stroke for heavy duty Temporary extra stroke to reach the areas to be welded Long working stroke to weld reinforcement ribs jobs in areas difficult to be reached etc Supplied complete with a 30 mA earth leakage switch different sizes upon request Oil less chromium plated cylinder and shaft for heavy duty operation and long life Lubrication is not necessary The selectors on the handle enable to choose two welding programs pressure only function Safety device placed on the handle preventing any accidental start Emergency push button in the welders with built in control unit Filter regulator pneumatic group with cutting device EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 OPTIONS UPON DEMAND e Double handle e Flow switch The following drawings enable to identify the
5. Inadequate welding force Oxidized pieces to weld Faulty pieces contact or pieces and electrodes faulty contact Faulty pieces lining up Electrodes tips deformations Too high welding current Inadequate electrodes diameter Inadequate welding force Increase it Increase it Reduce pressure Clean and line up the electrodes restore their dimensions Increase the electrodes force Clean the pieces Check the cooling circuit Increase the electrodes force by increasing pressure it it Adjust diameter to the suitable value Increase pressure to the suitable value Check stroke Reduce it Increase welding pressure Clean them by means of emery paper Increase electrodes force Correct their position Hestore them to the correct seize Heduce it Hestore it to the correct dimensions Increase the welding pressure Page 29 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 7 INSTRUCTIONS FOR THE ADJUSTMENTS 7 0 GENERAL INFORMATION The reading of this chapter assumes in order to safely use the welder the knowledge of what stated in Chapter 1 Paragraph 4 General Safety Warnings In addition the specific prescriptions to safely interact with the welder relevant to this chapter are detailed in the following paragraphs 7 1 STANDARD ACCESSORIES The welder is supplied equipped with the following accessories N 1 Allen wrench set N
6. The safety nut a must never be loosened or removed so to avoid the machine s fall off in case the nut Y1 is accidentally unscrewed EDITION MAY 2007 Page 34 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 BRAKE ADJUSTMENT FOR THE TRAVERSE By means of the three screws Y2 it is possible to adjust the gun s longitudinal rotation fluidity 3321 3322 3323 3324 3327 3328 ma E ux EMEN MANI 1 f WIES la RR UA 4 ares 3C Y 7 amp Dose the tightening force as far as obtaining the desired adjustment The three screws must be tightened using a uniform force Do not exceed with the tightening force this device has not been designed for carrying the traverse block out An excessive tightening force could damage it GYROSCOPIC ROTATION BLOCK A threaded lever x placed on the gyroscopic ring of the welder allows blocking the welder s transversal rotation This operation is useful for keeping the welder to the desired rotation angle Simply the block is obtained by tightening the threaded lever Do not exceed with the tightening force so not to damage the rotation system EDITION MAY 2007 Page 35 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 7 2 3 ARMS ADJUSTMENT OPERATOR QUALIFICATION NUMBER OF OPERATORS SAFETY MEASURES WELDER STATUS A oo A
7. WORKING STROKE SHORT TOTAL STROKE LONG MOBILE ELECTRODE POSITION WITH DISABLED DOUBLE STROKE LONG STROKE B MOBILE ELECTRODE POSITION WITH ACTIVATED DOUBLE STROKE SHORT STROKE This function may be used for two different purposes 1 Overcome the obstacles When spot welding pieces of great dimensions it would be necessary to have a high stroke to allow placing the pieces between the electrodes To allow using a reduced stroke in this working condition too the machine may be used with the double stroke In normal conditions one works with the short stroke and when necessary one may temporarily open the machine for overcoming the obstacle WORKING STROKE TOTALSTROKE I F LONG WORKING STROKE WORKING STROKE 2 Replacement of the electrodes By using a reduced working stroke the replacement of the electrodes may become a problem The double stroke function enables opening the electrodes to easily remove them The double stroke is controlled by a selector placed underneath the handle With the selector rotated in the front position the short stroke is obtained By rotating the selector in the back fixed position the long stroke is selected By simply carrying out a little rotation of the selector it is possible to obtain the temporary long stroke which is useful for overcoming the obstacles P 9 NORKING STROKE TEMPORARY LONG WORKING STROKE TOTAL STROKE WORKING STROKE
8. 3322 3323 3324 3327 3328 FAULT CAUSE REMEDY Inadequate welding force at the Inadequate welding pressure It is shown by the corresponding electrodes manometer Adjust it correctly by means of the pressure gauge The electrodes do not rise up after Inadequate welding pressure It is shown by the corresponding welding manometer Adjust it correctly by means of the pressure gauge Faulty adjustment of the flow Adjust it correctly regulator relevant to the opening speed V By pressing the start the control Inadequate or missing water Check that the water circulates in the unit displays THERMOSTAT OR circulation The flow switch SF1 or required quantity Check the FLOWSWITCH ACTIVED the thermostat protecting the thermostat functionality In case the transformer intervened flow switch is present check the water circulation direction Spots or electrodes overheating Insufficient cooling Check that water circulates in the required quantity and at a low Too high welding current or welding time temperature Pre welding Post welding TE450 or currents with too high time and or Modify too high current Electrodes reduced life Insufficient cooling Check that water circulates in the required quantity and at a low temperature Under seized electrodes in Check both seize and contact comparison with the work to carry diameter out Secondary connections reduced Insufficient cooling Check that water cir
9. 3327 3328 5 1 2 BUILT IN CONTROL UNIT TE450 WELD NON SALDA START Q wzoado PRG 2 RECALL RICHIAMO PRG 2 ausmanio LJ cornine Av FLETTROVAI VOLA I LJ TLETIROVAIVOLA 2 LJ NA MADE IN ITALY The welding control unit is used to control the welder parts and in particular the thyristor adjusting the welding current TE450 is a microprocessor welding control unit for resistance welding suspended spot guns This control unit includes specific functions to be used when working with suspended spot guns The handle is not a standard component of the welding control unit it is possible to install different handles so to set the machine according to different working needs It is possible to store up to 63 different welding programs it is possible to directly recall 2 programs by means of an external selector usually installed on the handle Each program is formed by 18 adjustable parameters describing the working cycle Besides the simple 4 times cycle the control unit enables to carry out welding processes with pre weld post weld current slope and pulses TE450 can work in constant current mode it displays the welding current and check the current according to set limits MAIN TECHNICAL DATA e Easy programming by means of 5 push buttons and LCD alphanumeric display e Synchronous thyristors drive with phase shift control for welding current adjustment 63 welding programs to be stored up 2 of them can be re
10. 56 Possibly reassemble a new gasket 57 Supply the welder again as follows 1 open the cooling circuit and check eventual water leaks 2 supply the compressed air 3 supply the machine by activating the supply switch J Start the welder as suggested in the instruction manual for commissioning mm mm mm mm mm mm part number mm mm 3x m o Aw _ passe sss A os os EDITION MAY 2007 Page 49 60 LORS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 9 SUPPLEMENTARY INSTRUCTIONS 9 0 GENERAL INFORMA TION The reading of this chapter assumes in order to safely use the welder the knowledge of what stated in Chapter 1 Paragraph 4 General Safety Warnings In addition the specific prescriptions to safely interact with the welder relevant to this chapter are detailed in the following paragraphs 9 1 WASTE DISPOSAL It will be care of the user in accordance with the relevant laws in force in his country to check the proper disposal of the waste produced by the machine during the specific production Furthermore he will have to manage the disposal for greases cooling liquids etc which are used in the machine for allowing its functionality If the user complies with the manufacturer s directives in its most significant parts he will obtain an improvement of the equipment functionality together with an eventual improvement of the production itself 9 2 OFF DUTY EQUIPMENT AND DISMANTLI
11. If it is necessary to grant the safety of the cutting device it is possible to add a lock in the hole of stem S To supply the welder press knob P Page 18 60 LCRS TECNA CONNECTION TO THE COOLING SYSTEM OPERATOR QUALIFICATION NUMBER OF OPERATORS o SAFETY MEASURES WELDER STATUS oo A Before performing the connection to the plant system check the perfect cleaning of the welder hoses they should be free from any external accidental remain of the unpacking or from storage in an inconvenient place For a proper cooling of the welder it is necessary to use clean water at a maximum temperature of 30 C in the quantity shown in the paragraph Technical Features When performing the connection pay attention that the hoses are free from dirt or from remains of package Then connect the supply to the inlet and the discharge to the outlet this is to allow the water which is still cold to reach the parts of the welder that are most subject to heating It is possible to have different water cooling systems by means of a closed circuit of a water air heat exchanger and by a water cooler If the circuit is closed or with a water cooler and the air in the working environment has a high percentage of humidity it is advisable to avoid water at a low temperature lower than 20 as this could cause moist inside the welder If water is hard or calcareous it is necessary to install a water softener at the inlet h
12. J o L jormw NOTES CONCERNING EITHER ELECTRODES OR WELDING TOOLS Electrode type and diameter maintenance and electrode replacement terms etc Enclose all other useful information for instance maintenance and electrodes replacement times notes on the pieces preparation etc EDITION MAY 2007 Page 56 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 10 4 TE450 PRODUCTION FORM FACSIMILE FIRM DATA Department WELDER DATA Welder Model Used arms type upper lower Used electrodes type upper tip diameter mm lower tip diameter mm PIECE TO BE WELDED WELDING PARAMETER ADJUSTMENT Foreseen working cycle SINGLE REPEAT Is during production foreseen the use of double stroke U YES UNO Welding pressure adjustment bar Obtained welding force daN Working stroke adjustment mm PARAMETERS ADJUSTMENT ON TE450 WELDING CONTROL UNIT ADJUSTMENT 1 ADJUSTMENT 2 No PARAMETER PARAMETER DESCRIPTION pROGRAM NO _ PROGRAMNO __ A woR wGMobE B CONTROLMODE e smoke 7 souezeTME1 O 2 SQUEEZE a PREPOWERCURRENT cop copmMEr e
13. Offset electrodes a pair 3722 4722 Angled offset electrodes a pair 3 23 4723 Bent electrodes a pair 3724 4724 Flat electrodes a pair 3725 4725 Swivel electrode 30 mm 4726 Electrode holder with electrode item 4727 ring nut and fittings 4727 Offset electrode for item 4726 4729 Offset electrode for item 4726 Model 3321 3322 3323 3324 3720 3721 3722 3723 3724 3725 Model 3327 3328 1 A wW ARNING On request the welding unit can be supplied with arms and or electrodes other than standard The listed items refer to the standard product EDITION MAY 2007 Page 53 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 10 2 WELDING TABLES In order to facilitate the search for the best welding conditions we have herewith inserted the following tables stating the approximate adjusting values Notice that the same weld can be carried out under different working conditions so much so that the following data are not binding ones Low carbon steel spot welding A welding class Thickness Spots Minimum Electrodes Electrodes Welding Welding Obtained minimum overlapping current nugget distance Thickness Minimum Welding minimum overlapping current a distance Lam DISTANCE BETWEEN SPOTS xee EDITION MAY 2007 Page 54 60 LORS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 Stainless steel 18 8 spot welding Thickness Spots Minimum Electr
14. advisable to adjust the electrodes with a fine file or with sandpaper The best performances can be reached by using sand paper folded upon a support having the same thickness of the sheets to be welded The diameter of the electrodes must be adjusted to a value suitable for the welding to be carried out The sheets thickness the kind of material and the chosen welding class must be taken into account The following values are suggested when welding steel The suggested electrode tip angle is 120 degrees If the thickness of the two plates is different the electrode must have the diameter corresponding to the one required by the plate to which it gets in touch 100 120 A too small diameter in comparison with the thickness to be welded produces spatters of melted material excessive mark on the sheets low spot quality If the electrode s diameter is too large longer welding times are necessary causing a higher heating of the welder and a shorter life of the electrodes Besides the truncated conic electrodes other electrodes types may be used like for instance spherical rounded flat tipped ones etc For all electrodes types do evaluate the proper electrode cooling EDITION MAY 2007 Page 39 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 7 2 5 WORKING STROKE ADJUSTMENT OPERATOR QUALIFICATION NUMBER OF OPERATORS SAFETY MEASURES WELDER STATUS A oo i Adjust the working stroke to the
15. for carrying the intervention out are described here below A Stop the electric pneumatic and cooling supply so that NOBODY CAN SUPPLY THE WELDER BEFORE HAVING COMPLETED AND CHECKED THE INTERVENTION A Open up the lid 51 of the cable connection box by removing the nut 38 and the screws 56 B Unscrew the nut 52 and the two screws 55 remove the 3 washers 53 and the cable 30 C Identify the position in the cable 30 where the damage occurred R1 If the circumstances allow it repair the cable otherwise replace it Cable repair Cable replacement D Cutthe cable 30 10 cm beyond the breaking point D Open the switch box and remove the cable 30 E Arrange the cable as per the following drawing The E Check that the replacement cable is the correct one cable diameter L must be perfectly cylindrically for the machine and connect it to the switch restored by means of self agglomerating tape or similar one Follow the tape manufacturer s instructions EDITION MAY 2007 Page 48 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 F Reassemble the cable by tightening the 3 cable lugs with the 2 screws 55 and the nut 52 with a suitable tightening pair G Check the perfect work execution distances as per drawing painstaking insulating well tightened screws free to move cable in a position not to undergo any stress H Reassemble the lid 51 of the cable connection box by tightening the nut 38 and the screws
16. minimum possible value to obtain Reduced accident possibilities Reduced noise Bigger productivity Faster force rise time on the pieces to be welded Higher follow up Higher working precision Reduced air consumption NOOR WD The stroke adjustment must be carried out in order to avoid that the cylinder reaches the end of the stroke limiting or clearing by doing so the force on the piece Remind that both electrodes wear and arms deflection increase the working stroke A ADJUSTMENT IN THE C TYPE WELDERS ITEM 3323 The working stroke may be modified by shifting the lower arm carry the following operations out 1 Stop the electrical pneumatic and the cooling water supply 2 Loosen the screws M 3 Adjust the working stroke by rotating the ring nut J by means of the pin driver supplied with the standard accessories 4 Perfectly align the electrodes A 5 Tighten the screws M with a pair of 24 26 Nm This type of operations must be carried out when the machine is on therefore one must operate using the maximum caution and carefulness Carry out some tests with the control unit on NO WELD mode using the same electrodes force employed to carry out the work place between electrodes a thickness equal to that which must be welded Do not tighten the screws M if the arm is not fitted EDITION MAY 2007 Page 40 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 A ADJUST
17. possible to use the welder When on PRESSED position the welder functioning is disabled The electrodes maintenance must always be carried out when having this button in the PRESSED position 5 5 RESIDUAL RISKS The welder main risk is the squashing of the upper limbs caused by the moving of the electrodes It is therefore necessary to pay careful attention and follow all the instructions included in instruction manual particularly e Adjust the welding stroke to the minimum possible value Avoid working having the hands close to the electrodes A G 9 Notice that these types of machines generate strong magnetic fields attracting metals and damaging watches magnetic cards and magnetic data storage media Since these magnetic fields can affect pace makers hearing aids and any electric medical device the wearers must consult their doctor before approaching to the welding area The personnel must wear safety glasses gloves and accident prevention shoes Avoid wearing rings metal watches and clothes with either metal accessories or components Page 25 60 LORS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 6 MACHINE USE 6 0 GENERAL INFORMA TION The reading of this chapter assumes in order to safely use the welder the knowledge of what stated in Chapter 1 Paragraph 4 General Safety Warnings In addition the specific prescriptions to safely interact with the welder relevan
18. rating The following paragraphs carefully explain these different phases Before starting the working process Check that all the safety instructions have been operated Check that the automatic cycle is inserted only when it is really used e Check that the pneumatic circuit is supplied e Check the correct functioning of the control devices Carry out some test cycles in order to verify both the cycle correctness and the operating speeds These tests should be carried out without current circulation by means of the WELD NO WELD selector placed on the control unit Before starting the welding process check the welding conditions time pressure etc Use two off cuts of the sheet to weld carry out two spots at the same distance used during the production then remove the first and check the second the spot is correct when the pulling test causes the coming out of the weld nugget with the hole of a sheet and the twist test shows a pure area without porosity or causes the coming out of the nugget EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 FIRST SPOT PULLING TEST During the production it is advisable to monitor those parameters which can alter the working conditions and thus the welds quality Always monitor the electrodes which must always be clean without any deformation and must have the proper diameter according to the work to be carried out Check that there is no strong ch
19. to quickly and easily provide the information necessary to the proper use of the welder under safe conditions GLOSSARY DANGEROUS AREA An area inside and or close to the welder in which the presence of an exposed person is risky for the safety and the health of the same person Enclosure l 1 1 1 Directive 98 37 CE EXPOSED PERSON Any person who is fully or partially in a dangerous area Enclosure 1 1 1 Directive 98 37 CE OPERATOR The person in charge for installing working adjusting maintaining cleaning repairing and transporting the welder Enclosure 1 1 1 1 Directive 98 37 CE INTERACTION MAN MACHINE Any situation in which an operator acts with the welder in any of the operation phases and in any period of the life of the welder OPERATOR QUALIFICATION Minimum skills level an operator must have to carry the described operation out OPERATORS NUMBERS Suitable number of operators for carrying the described operation out in good conditions This is the outcome of a careful analysis of the manufacturer s should the operation be carried out by a different number of operators this could either prevent from obtaining the expected result or endanger the involved personnel s safety RESIDUAL DANGER Danger which was not possible to remove sufficiently reduce by means of the engineering The protections are not or are not totally effective against this danger The instruction manual informs about its exi
20. welders main parts and to learn the terms used in this manual Page 9 60 LORS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 22 IDENTIFICATION OF THE WELDER MAIN PARTS WELDERS L TYPE ITEM 3321 3322 3324 3327 3328 2 gt Electrodes Lever movable Electrode holder Upper arm fixed Lower arm movable Front cover Stroke adjustment system Protection for the stroke adjustment system Flow switch option Suspension arm Gyro ring Gyro ring lock Balancing adjustment guide EDITION MAY 2007 Horizontal balancing stop Handle Additional handle option Control unit Valves for stopping the water cooling system Flexible cable guide Cable connection box Supply cables and hoses Emergency stop button Double stroke selector Adjustment of electrodes opening speed Adjustment of electrodes closing speed Page 10 60 LCRS TECNA WELDERS TYPE ITEM 3323 Electrodes Adjustable fixed arm Movable electrode holder Movable electrode holder protection Electrode holder connection head Front cover Front hoses protection Stroke adjustment Flow switch option Suspension arm Gyro ring Gyro ring lock Balancing adjustment guide A B C D E F G H no EDITION MAY 2007 N lt DO SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 Horizontal balancing stop Handle Additional handle option
21. when operating pieces with different thickness the welding parameters to be used are those which refer to the lower thickness This welder can operate under two different working modes single cycle and automatic cycle The adjustment instructions are stated on the welding control unit instruction manual When working in automatic cycle as long as the start cycle control device is activated the welder will repeat welding cycles at the settled off time In single cycle even though the start device is kept activated the welding unit will stop after having carried out a single cycle to carry out the next one it is necessary first to release the device and then press it once again 1 SELL o avoid any danger use the automatic cycle only when it is really necessary it must not be activated when it 15 not used Adjust SQUEEZE time at a value high enough to enable the electrodes to reach the pieces to be welded as well as the chosen force before the welding current is activated especially in case of long stroke or reduced speeds SQUEEZE SQUEEZE Insufficient Squeeze Correct Squeeze When the welding time is over the electrodes must be kept closed for a few moments the elapsing time is called HOLD time This precaution enables to improve the weld quality We recommend setting this parameter to a value corresponding to the half of the one chosen for the welding time EDITION MAY 2007 Page 45 60 LCRS TECNA 8 MAINTE
22. 1 Electrodes extractor N 1 Pin driver 3 for Item 3323 N 1 Stroke adjustment key for Items 3321 3322 3324 3327 3328 1 High conductivity grease sample 1 Rotating supplementary handle 1 Filter regulator pneumatic group with cutting device 1 Welding control unit instruction manual 1 Welder installation and use manual 1 Technical documentation booklet N 1 Clips set replacement screws and little accessories N N N N N N Check that the machine is complete with all the standard accessories promptly inform the manufacturer of all the eventual missing parts 72 MECHANICAL SET UP 7 2 1 ARMS SELECTION AND REPLACEMENT OPERATOR QUALIFICATION NUMBER OF OPERATORS SAFETY MEASURES WELDER STATUS A OS The lengthening of the arms causes a decreasing of the performances so that it is advisable always to work with the shortest available length Besides allowing obtaining better quality welds this adjustment enables improving the machine s handling When carrying the arms replacement out it is advisable to block all the welders movements by means of the suitable brakes and to also block the balancer vertical stroke This prevents the machine from moving because of the weight change A The improper use of the balancer block device may involve serious risks Refer to the balancer instruction manual Carefully read the balancer instruction manual and scrupulously follow its indications The operation
23. CTIVITY GREASE or equivalent remove the exceeding grease after tightening the parts so to prevent from short circuits MINERAL or SYNTHETIC OIL with MOLIKOTE M 55 PLUS additive at 10 EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 GENERAL WARNINGS A Always disconnect both electrical and pneumatic supply before carrying out the following maintenance operations e The secondary circuit contacts must be kept clean Fine sandpaper can be used for cleaning After cleaning apply a light veil of conductivity grease on the contact parts Once the parts are assembled remove the exceeding grease so to prevent from short circuits e Always keep the screws of arms electrode holders and rigid flexible connections well tightened Periodically each 3 months grease the gyroscopic ring venue by means of the proper greaser placed on the ring itself Carefully remove the exceeding grease Check that the flexible connection is undamaged Eventual broken laminates must be removed so to prevent them from causing short circuits If the flexible connection is excessively worn out replace it e Keep welder clean from dirt and metal scraps attracted by the magnetic field generated by the welder during the operation e Neither washing the welding unit with jets of water which could enter it nor use strong solvents thinner nor benzine that could damage either the painting or the machine plastic components EL
24. Control unit Valves for stopping the water cooling system Flexible cable guide Cable connection box Supply cables and hoses Emergency stop button Double stroke selector Adjustment of electrodes opening speed Adjustment of electrodes closing speed Page 11 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 2 3 TECHNICAL DATA ITEM FREQUENCY SUPPLY VOLTAGE ss ssz ssm 3927 sse Delayed fusesaeoooaisv s2 40 40 40 so 80 _ Amsta mm 3e 36 o 4 Electrodes taper 127 127 127 127 38 Gosupensong mm 2 2 5 265 265 294 294 _ m f 10 wm em m om Maximum eleoroses free Gba een ze sm so 268 ee 5 _ mm 628 820 ses 6 25 1086 10 _ Maximum svoe mm 3048 28 40 35 50 35 50 4560 46 60 m em ew s we 9 Maximum electrodes torse 6ba dav 95 7 1 195 mm 1560 40 BTS e LL Net weight including cables hoses gyro suspension and shortest arms Balancer capacity with short arms kg 50 55 05 60 55 60 60 65 80 90 80 90 with long arms kg 05 60 65 70 65 70 95 105 95 105 Packing dimensions 300x850x550 330x1120x630 760x1050x500 OPTIONS J 3316 TE450 Welding control unit O 3318 Flow switch which ma
25. DJIUSTMENTT iret ovatae erp a a 74 WORKING PROGRAM 05 8 MAINTENANCE n 9 0 GENERAL INFORMATION ui putres ctu inse Save tuia 8 1 ORDINARY MAINTENANCE 8 2 EXTRAORDINARY 8 2 1 LOWERING OF THE WELDING UNIT 8 2 2 REPAIR OR REPLACEMENT OF THE SUPPLY CABLE 9 SUPPLEMENTARY INSTRUCTIONS rens aeaa 90 CGENERBALINEORM ATIONJ Draper Ue te 9 1 WASTE DISPOSAL tuii cuti dimus dead edi tein tt vp 9 2 OFF DUTY EQUIPMENTAND DISMANTLING eeeeseseeeennnnnnn nnne 93 EMERGENCY CONDITIONS INSTRUCTIONS seen 10 ENCEOSUHES osa E MEL DIUI M UU ML 10 0 GENERAL INFORMATION sese nnnm 10 1 ACCESSORIES AND SPARE PARTS REQUEST eese 10 2 WELDING TAB ES pati ERR EA Ete ipa EIS ee Rapp ovii nU p aA ERN QUU RUF cod 10 3 TES300 PRODUCTION FORM FACSIMILE sese 10 4 TE450 PRODUCTION FORM FACSIMILE
26. DJUSTMENT IN THE C TYPE WELDERS ITEM 3323 Under working conditions both arms and electrode holders must be adjusted in order to have the electrodes tips coincide The adjustment is carried out by rotating the arm and where foreseen by carrying out the vertical alignment of the fixed electrode holder To rotate the arm 1 Stop the electrical pneumatic and the cooling water supply 2 Loosen the screws M so to free the arm Rotate the arm so that the two electrodes are in axis 4 Tighten the screws M with a pair of 24 26 Nm a 4 This type of operations must be carried out when the machine is on therefore one must operate using the maximum caution and carefulness Carry out some tests with the control uniton NO WELD mode using the same electrodes force employed to carry out the work place between electrodes a thickness equal to that which must be welded ss ESET Do not tighten the screws M if the arm is not fitted EDITION MAY 2007 Page 36 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 ADJUSTMENT IN THE L TYPE WELDERS ITEMS 3321 3322 3324 3327 3328 Under working conditions both arms and electrode holders must be adjusted in order to have the electrodes tips coincide If necessary it is possible to carry the adjustment out by moving the upper electrode holder and or the lower arm The lower arm may be shifted by carrying the following
27. ECTRODES MAINTENANCE A Electrodes maintenance must be carried out with the welder switched off When operating the electrodes must be kept clean and their diameter must be kept suitable for the work to be carried out Too worn electrodes must be replaced e When replacing electrodes check that the tube bringing water to the electrode inside stops at a few mm from the bottom of the electrode hole Do not use sealing products to remove water leakage on the electrode taper To facilitate the electrode removal and to prevent from both taper seizure and leakage use high conductivity grease like the one delivered in the standard equipment Before replacing the electrodes stop the water supply circuit or stop the electrodes cooling circuit by means of the valves placed on the welder side A WARNING Before starting the production again always check that the cooling circuit has been reopened Page 46 60 LCRS TECNA PNEUMATIC CIRCUIT MAINTENANCE A The pneumatic circuit maintenance must be carried out by specialized personnel only trained to accomplish it under safety conditions When possible maintenance operations must be carried out with the welder switched off and disconnected from the pneumatic supply with the circuit free from left air e Incase of air leakage immediately stop operating and remove it e Check the proper functioning of the automatic air filter discharge Check pressure gauge cali
28. GE OF THE WELDER BOTH PACKED AND UNPACKED For all the time the welder in not used before unpacking store it in a dry place with an environment temperature included between 0 C and 40 C and in such a position so that it not in contact with the rain FOR STOCKAGE ONLY if water cooling system is emptied the welder can be kept up to 20 C Protect the welder during the whole period of inactivity for example before being installed or in case of production stop after its unpacking Page 14 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 3 4 UNPACKING Handling of the welder without suspension arm UNPACKING OF PALLET WITH PROTECTIVE FILM Transport the welder close to the place of installation then Take off the plastic protection which covers the welder paying attention not to damage it Visually check the external integrity of the welder Check that the welder is complete with all the standard accessories should some parts be missing immediately inform the manufacturer All the material forming the package must be scrapped according to the present environmental safety regulations 3 5 HANDLING OF THE UNPACKED WELDER OPERATOR QUALIFICATION NUMBER OF OPERATORS 1 Handling of welder with suspension arm SAFETY MEASURES WELDER STATUS oo NOTICE The transport of the unpacked welder should be performed by skilled personnel by means of either a fork elevator or strip chain
29. LORS TECNA 1090 LOUSONS ROAD UNION NEW JERSEY 07083 USA Tel 908 964 9100 Fax 908 964 4492 email sales lors com AIR OPERATED PRODUCTION SPOT WELDING GUNS MODELS 3321 3322 3323 3324 3327 3328 INSTRUCTION USER MANUAL EDITION MAY 2007 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 INDEX 0 INTRODUCTION 5 0 1 PURPOSE OF THE INSTRUCTION MANUAL tton 5 0 2 KEEPING OF THE INSTRUCTION MANUAL tette tet tete tette 5 0 3 HOW TO UPDATE THE INSTRUCTION MANUAL eet 5 1 GENERAL INFORMATION ccrte ttt ntt ttt stores tetas sss DEP DEP DEEP DEUS 6 1 1 MANUFACTURER IDENTIFICATION DATA rtt tette tette tette ett 6 i2 TENT TON DA 6 1 3 INFORMATION ABOUTTECHNICAL ASSISTANCE eere treten 6 1 4 GENERAL SAFETY RULES 6 1 5 GLOSSARYAND SYMBOLS ON THE WELDER AND IN THE MANUAL 7 2 INFORMATION ABOUT THE WELDER erret ttt ttes stesso sss snnt AS 9 21 DESCRIPTION OF THE WELDER MAIN FEATURES eee 9 22 IDENTIFICATION OF THE WELDER MAIN PARTS eeeee eee 10 23 ss eset eiat E D DE 12 24 BORESEEN USE tieu timeri dentes tnmen itte trem 13 TRANSPORT AND HANDLING ssscssceccescosssecsessessecuesucsussaesaessesstssuesucsussutsaesaesatsstesessessesuesssatsatessesees 14 3 0 GENERAL INFORMATION cccccccsceccescsessesce
30. MENT IN THE L TYPE WELDERS ITEMS 3321 3322 3324 3327 3328 Before adjusting the working stroke check that the arms when clenching the pieces to be welded are parallel This operation must be carried out when having the stroke selection trigger on short stroke The working stroke adjustment is carried out by proceeding with the following operations 1 Stop the electrical pneumatic and the cooling water supply 2 Loosen the ring nut B with the key A Rotate the screw C with the 5 mm Allen spanner D for adjusting the working stroke 4 Once the adjustment is done tighten the ring nut B again This type of operations must be carried out when the machine is on therefore one must operate using the maximum caution and carefulness Carry out some tests with the control unit on NO WELD mode using the same electrodes force employed to carry out the work place between electrodes a thickness equal to that which must be welded When adjusting the stroke pay attention that the machine s movable lever DOES NOT touch the suspension gyroscopic ring when operating in long working stroke condition EDITION MAY 2007 Page 41 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 7 2 6 DOUBLE STROKE USE All the welders are equipped with the double stroke that is to say a device enabling using two different strokes of the electrodes the short stroke or working stroke and the long stroke or full stroke
31. NANCE 8 0 GENERAL INFORMATION The reading of this chapter assumes in order to safely use the welder the knowledge of what stated in Chapter 1 Paragraph 4 General Safety Warnings In addition the specific prescriptions to safely interact with the welder relevant to this chapter are detailed in the following paragraphs 8 1 ORDINARY MAINTENANCE OPERATOR QUALIFICATION NUMBER OF OPERATORS SAFETY MEASURES WELDER STATUS G This chapter states the necessary maintenance operations to be carried out for 1 keeping the welding unit safe operating and preserving its efficiency 2 avoiding the most common causes of wrong working worsening the welding quality A During the maintenance operations it is advisable to block the balancer for further information check the balancer instruction manual A We remind that besides carrying the machine maintenance operations out it is necessary to carry the balancer maintenance out by following the instructions included in the relevant instruction manual For all interventions involving disassembling the machine kindly refer to the exploded views showing the parts and their position We recommend maximum cleaning oxidations removal use of lubricants and prescribed products LUBRICANTS The suggested lubricants for the welder are listed in the technical documentation e POLIMER 400 GREASE or equivalent e MOLIKOTE G N PLUS GREASE e VANOFRIX 430 CONDU
32. NG The machine is composed of the following materials STEEL PLASTIC MATERIALS PLEXIGLASS TEFLON DERLIN POLIZENE ELECTRIC COMPONENTS LUBRICATING GREASE COOLING LIQUIDS FOR THE MACHINE DISMANTLING SCRUPULOULY COMPLY WITH THE INDICATIONS PROVIDED BY THE LAWS IN FORCE IN ONE S COUNTY 9 3 EMERGENCY CONDITIONS INSTRUCTIONS IN CASE OF FIRE DO EXCLUSIVELY USE POWDER OR CARBON DIOXIDE EXTINGUISHERS EDITION MAY 2007 Page 50 60 LORS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 10 ENCLOSURES 10 0 GENERAL INFORMATION The reading of this chapter assumes in order to safely use the welder the knowledge of what stated in Chapter 1 Paragraph 4 General Safety Warnings In addition the specific prescriptions to safely interact with the welder relevant to this chapter are detailed in the following paragraphs 10 1 ACCESSORIES AND SPARE PARTS REQUEST When ordering accessories spare parts or expendable material please always state type of machine year of manufacture serial number the voltage and frequency of the welder they must be assembled on Look at the exploded views and at the spare parts list to identify the item number of the required parts The first number of the item number has the following meaning 1 Standard components widely available from industrial suppliers e g screws nuts washers etc 2 Commercial components which providing that the same quality parameters are adopted can be pur
33. ON DATA ITEM SERIAL NUMBER YEAR OF MANUFACTURING ARMS CONTROL UNIT SUPPLY VOLTAGE CABLES LENGTH PNEUMATIC GROUP EDITION MAY 2007 1 3 INFORMATION ABOUT TECHNICAL ASSISTANCE The welding machines of the manufacturer are covered by warranty as per general sales conditions If within the validity of the warranty defective workings of the welder or faults which are included in the warranty clauses are detected the manufacturer will take care of repair or replacement of faulty parts after his technical evaluation on the welder It is reminded that even slight modifications made by the user without written authorization by the manufacturer invalidate the warranty and discharge the manufacturer by any responsibility for damages caused by a defective product This is valid especially in case above modifications are made on safety devices invalidating their efficiency The same prescriptions are valid when using non original spare parts or spare parts different from the ones explicitly informed by the manufacturer For all the above reasons we suggest to our customers to call our Technical Service for any problem 1 4 GENERAL SAFETY RULES A Before using the welder it is necessary to carefully read the instructions in this manual and carefully follow its prescriptions The manufacturer has designed this welder to be INTRINSICALLY SAFE as much as possible The welder has been equipped with all the pro
34. SEMBLY SUSPENSION SYSTEM OPERATOR QUALIFICATION NUMBER OF OPERATORS o SAFETY MEASURES oo The suspension arm is supplied disassembled from the welder therefore it is necessary to assemble it as per the following drawing It is important to mount and well tighten the safety nut a so that the fall of the welder is avoided in case Y1 nut is accidentally unscrewed WELDER STATUS Prepare a suspension suitable to the work to be made It is advisable to suspend the welder to a balancer which enables the operator to use the welder with the minimum effort A The installation of the balancer is a seriously risky operation Carefully read the balancer instruction manual and follow its prescriptions Models 3321 3322 3323 3324 ONE SI TEN 2 il ONY AT LII 1m Safety nut Bearing Bushing Bushing Suspension washer Suspension screw Suspension arm Suspension locking nut Headless screw lt lt N EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 The balancer should be equipped with a device which electrically insulates the welder from the structure to which it is suspended this avoids an eventual current flow of the welding current to the suspension system Rotary insulated hooks can be used for this purpose they also avoid having twists on the balancer rope When the balancer and the safety rope has been hooked to
35. agraph The minimum diameter of the hoses mentioned in the same paragraph example A should be taken into consideration In case the line is subject to high pressure changes it is advisable to supply the welder with a tank sized at least 25 50 litres which is supplied by means of a one way directional valve example B ALIMENTAZIONE SALDATRICE WELDER SUPPLY ALIMENTAZIONE SALDATRICE WELDER SUPPLY Pneumatic installation examples Control knob Blocking hole with lock Compressed air supply Compressed air outlet for welder Cutting device opening extract the knob P Cutting device closing press the knob P Owrwn wv EDITION MAY 2007 The welder is equipped with a filter which automatically discharges the mist and it must absolutely be installed in a vertical position The welder is manufactured with components which do not require lubrication If a component which requires lubrication is installed in the welder attention has to be paid to the fact that this implies emission of oil mist in the environment A device to cut the pneumatic supply is installed in the filter group Besides being hand operated this device automatically disconnects the supply when the pressure goes beyond 3 4 bar This enables to avoid sudden movements in case of a temporary absence of the pneumatic supply To cut the supply of the compressed air for example when you need to perform maintenance operations take out the knob P
36. anging in the welder supply pressure as this could modify the force at the electrodes and thus the welding quality Do not use sealing products to remove water losses on the electrodes conic connection To facilitate the electrode removal and to prevent from both cone seizure and water losses use high conductivity grease like the one delivered in the standard equipment The cooling water must circulate inside the welder for a few minutes after having completed the production in order to allow the welder cooling To prevent from both losses and moisture deposits do not leave the cooling circuit open when the unit is not used Electrodes must not be used to force the clamping of the pieces to weld We recommend you to notice the adjustments carried out for each type of piece In order to make it easier a specific table has been added at the end of this manual Page 24 60 LCRS TECNA DESCRIPTION OF THE CONTROL DEVICES The welding cycle start is obtained by acting on the cycle start button 1 As long as the welding process has not starter the gun would immediately reopen if the cycle start button is released These welding guns are equipped with a safety micro switch 2 placed on the handle s back This one enables the cycle start only if the operator grasps the handle The button 3 placed on the handle s side allows using the PRESSURE ONLY function Usually this device is used for checking that the electrodes ar
37. bration e Check the status of both compressed air and corresponding connections e Watch out not to introduce either dirt or dust in the machine which may cause serious damages stop or quick wear COOLING CIRCUIT MAINTENANCE A The cooling circuit maintenance must be carried out by specialized personnel only trained to accomplish it under safety conditions When possible maintenance operations must be carried out with the welder disconnected from both electric and pneumatic supply e Check that cooling water circulates freely and in the required quantity and that the input temperature is included within 10 and 30 C e Check the status of both water hoses and the corresponding connections If during the winter terms the welder must be stored up in cool rooms it is necessary to carefully drain the cooling circuit to prevent from possible damages caused by frozen water ELECTRIC CIRCUIT MAINTENANCE A The electric circuit maintenance must be carried out only by specialized personnel trained to accomplish it under safety conditions Disconnect electric mains before carrying out the following instructions as mortal discharges may be received from the supply Frequently check the welder supply cable status Pay special attention to the points where the cable gets mainly stressed or exposed to possible mechanical damages Replace it in case cracks cuts heavy abrasions are found e Check that the welder is con
38. called from an external device 18 programmable parameters for each program Slope pulses pre weld and post weld functions e Welding times adjustment in half periods Display of both welding current in kA and relevant conduction angle Double working mode standard and constant current Either welding current or conduction angle limits e Stepper function to balance the electrodes wear with adjustable curve e Welds counter e Compensation of secondary current to weld oxidized sheets and rods e Single and automatic cycle WELD WELD function Delay of first phase shift adjustment to get the best balance of the machine absorption from the mains Control of 2 solenoid valves 24 Vdc 7 2 W Max with protected output against short circuit electrode closing valve and double stroke valve For further information concerning TE450 see relevant instruction manual EDITION MAY 2007 Page 21 60 LCRS TECNA 5 2 ELECTRIC GENERAL SWITCH Emergency Interruption 9 Following to a dynamic type action and while being supplied the machine is designed for being stopped in EMERGENCY INTERRUPTION conditions operator by acting on the machine s general switch so to remove an electric danger A The placing in service of the welder after an emergency condition must be carried out only by qualified personnel trained to accomplish all the machine necessary tests If the machine was stopped during the welding proc
39. ccecsecsecsecsecsecsecsaessessuccecsecsecsecsarsasssecsessessecsucsacssessesscsecseteess 14 14 3 2 TRASPORT AND HANDLING OF THE PACKED WELDER eed 14 33 STORAGE OF THE WELDER BOTH PACKED AND UNPACKED eeeteeed 14 gA UNPACKING DRAN ANAND 15 35 HANDLING OF THE UNPACKED 15 4 INSTALLATION iia no tmt esto eee tte EM IL HM RM LEE 16 4 0 GENERAL WARNINGS stich terete tea PM MIR MN M ME EE 16 4 1 REQUIRED ENVIRONMENT CONDITIONS cccscsccsceccesssssseccecsescecsecsecsecsecseessessecsecsersucsecsersecsatsateseerees 16 4 2 LOCATION THE WELDER 2 265 LL p D LI EAE 16 4 3 ACCOMPLISHMENT OF THE ASSEMBLY cccccccscescescsessecceccecseccecsecsecsecseeseesseesecsersersecsecsatssessessesseeeees 17 44 CONNECTION TO THE ELECTRIC SUPPLY teet tette tentent 18 5 WELDER SET UP scscscsessessescescessesssecucsussussaesstsseessesucsussussassassassussatsaesstssuesussassussatsaesatssuesatsassassateseeseesess 20 5 GENERAL NOTIOE c at ua o 20 5141 DESCRIPTION OF THE WELDING CONTROL UNIT 20 5 1 1 BUILT IN CONTROL UNIT T5900 20 5 1 2 BUILT IN CONTROL UNIT TEABO certae a ote mitteilte editur e o ie asd 21 5 2 ELECTRIC GENERAL SWITCH Emergency Interruption nnns 22 53 SAFETY RULES IC Mn mU IE D M MM ED ME EE E 22 54 MACHINE FUNCTIONING eerte ttt te tete tet
40. chased anywhere switches hoses etc Components manufactured by TECNA Components manufactured by TECNA Electronic circuits manufactured by TECNA Assemblies composed of parts belonging to any or all of the above codes but which for the sake of simplicity are available ready assembled The code number followed by an asterisk warns that the part changes depending on the mains voltage All spare parts including standard or commercial ones are available from TECNA OAO ACCESSORIES e 3311 Removable key selector for programming lock for TE300 3312 Removable key selector for programming lock for TE450 3313 Holder to mount the control handle on the lower side of the spot gun for items 3321 3322 3323 3324 e 3314 Holder to mount the control handle on the lower side of the spot gun for items 3327 3328 e 3315 Holder to mount the control handle on a spot gun side complete with another handle without control ARMS Item 3323 60 5 205 e mmm m E Art 4883 Standard lower arm G Art 4884 Reduced dimension lower arm F Art 4882 Upper electrode holder F Art 4882 Upper electrode holder EDITION MAY 2007 Page 51 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 ARMS Item 3321 3322 3324 3327 3328 Item 3327 3328 EDITION MAY 2007 Page 52 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 ELECTRODES 3 20 4720 Straight electrodes a pair 3721 4721
41. cooling circuit Loosen the screws M By means of the pin driver standard supplied rotate the ring nut J as far as extracting the arm B Carefully clean the venue and the end of the new arm Check that the gasket n and the conic venue of the electrode are not damaged Spread a light veil of conductivity grease on the end of the new arm Fit the new arm caring to check the perfect entering of the tube m inside the cooling circuit by rotating the ring nut J as far as bringing the same to the necessary position this operation allows adjusting the working stroke to the desired value Perfectly align the electrodes A and tighten the screws M with a pair of 24 26 Nm After replacing the arm it is necessary to adjust it see paragraph 7 2 3 ARMS ADJUSTMENT Do not tighten the screws M if the arm is not fitted Side view Front view 7 IN EDITION MAY 2007 Page 32 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 A A ARMS REPLACEMENT IN THE L TYPE SUSPENDED WELDING GUNS ITEM 3321 3322 3324 3327 3328 Stop the electrical supply at the main switch supplying the welder Close the pneumatic supply and discharge the remaining air The cutting device supplied with the machine accomplishes this task Close and discharge the water from the welder cooling circuit Loosen the screws M Remove the arms A without rotating them Carefully clean the venue and the
42. culates in the life required quantity and at a low temperature Heating caused by an inadequate Carefully tighten the clamping clamping of the flexible connection screws Too high heating caused by a too Reduce it high welding rate EDITION MAY 2007 Page 28 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 6 3 REMEDIES FOR WELDS IMPERFECTIONS This chapter has been introduced in order to facilitate the troubleshooting of the most common imperfections caused by a wrong adjustment Notice that each fault can be caused by different causes as there are many parameters affecting the welding process The following table specifically refers to low carbon steel spot welding but with the due considerations it can be used for other applications also FAULT POSSIBLE CAUSE POSSIBLE REMEDY Weak welding Spatters of melted material Burned welds or welds showing either craters or fissures Pieces stuck weld on the electrode EDITION MAY 2007 Low welding current Low welding time Too high electrodes force Lacking electrodes maintenance or too high electrodes diameter Faulty pieces contact Paint or dirt among pieces Inadequate electrodes cooling Faulty pieces contact or pieces and electrodes faulty contact Too high welding current Too high welding time Too small electrodes diameter Inadequate welding force Electrodes faulty clamping of the pieces Too high welding current
43. de Identify what caused the fault Check the control unit intervened the wiring Replace the fuses Cut supply cable Check and eventually intervene as described in 8 2 2 Check fuse on boards for TE450 Replace the fuses The control unit does not switch Inadequate mains voltage on The welder carries out the welding WELD NO WELD function set to Set to WELD cycle without current circulation NO WELD Control unit CURRENT led is off Fault Rep The welder unit carries out the Faulty contact in the secondary Check and tighten all the secondary welding cycle without current circuit connections Do not forget the circulation The control unit connection between the electrode CURRENT led lights and the electrode holder No electrode descent Welding Lack of compressed air It is shown by the corresponding control unit led EV1 lights manometer Operate Inadequate welding pressure It is shown by the corresponding manometer Increase it by means of the pressure regulator Broken connection between the Check control unit and the solenoid valve Faulty solenoid valve EV1 Replace it Too slow or not uniform electrodes Inadequate welding pressure It is shown by the proper pressure descent gauge Adjust it correctly by means of the pressure gauge Faulty adjustment of the flow Adjust it correctly regulator relevant to the closing speed Z EDITION MAY 2007 Page 27 60 LORS TECNA SUSPENDED SPOT GUNS 3321
44. e correctly placed before carrying the welding process out By activating the control PRESSURE ONLY by pushing the button 3 while the electrodes close the welder clenches the pieces to be welded and wait for the operator to conti nue the cycle by removing the control PRESSURE ONLY by releasing the button once he has checked that the electrodes are correctly placed If the electrodes are correctly placed then the operator may cancel the operation by releasing the cycle start control The selector 4 enables to quickly select two different welding parameters adjustments The adjustment selection must be carried out before the welding cycle Start For further information please refer to the control unit instruction manual Upon demand the welding gun may be equipped with other handles to have it suitable for the different working needs EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 KEY SELECTOR FUNCTION OPTIONAL Upon demand the welding control unit may be equipped with a two position key selector This one allows disabling the control unit programming when one wishes that the user cannot modify the welding programs By positioning the key according to the black reference all programming operations will be inhibited e BLACK DISABLED PROGRAMMING e RED ACTIVATED PROGRAMMING EMERGENCY SWITCH An EMERGENCY button is placed in the machine s rear part When on NORMAL position it is
45. ectrode holder cone The electrode extraction may be carried out by means of either a key or the suitable extractor supplied with the standard accessories To facilitate the electrode removal and to prevent from taper seizure spread a light veil of high conductivity grease on the cone This procedure is mainly advisable when the cone has extremely reduced angles It is possible to extract the electrode in two different ways 1 Extraction by axial movement By using the extractor supplied with the standard accessories it is possible to apply an axial force with the extractor prizing between the electrode and the electrode holder 2 Extraction by rotating movement By either using the extractor supplied with the standard accessories or a key apply a rotating force 1 Extraction by axial movement 2 Extraction by rotating movement In the C type welders item 3323 one must pay attention to force neither the electrode holder nor the cylinder If the electrode is extracted by rotating movement do support the effort with a key fitted on the electrode holder C EDITION MAY 2007 Page 38 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 A This type of operations must be carried out when the machine is on therefore one must operate using the maximum caution and carefulness To prevent from cooling water leakage when the machine is off close the circuit delivery taps placed on board the machine It is
46. end of the new arms Fit the new arms A Pay careful attention to the complete fitting of the arms as far as they are correctly placed in the reference working position 8 Tighten the screws M with a pair of 12 13 Nm N N After replacing the arm it is necessary to adjust it see paragraph 7 2 3 ARMS ADJUSTMENT Do not tighten the screws M if the arm is not fitted EDITION MAY 2007 Page 33 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 7 2 2 SUSPENSION ADJUSTMENT OPERATOR QUALIFICATION NUMBER OF OPERATORS SAFETY MEASURES WELDER STATUS A oc 9 The suspension adjustment is an operation allowing obtaining the greatest welder maneuverability in the working condition to be carried out Besides the adjustments on the welder which are listed here as follows it is necessary to carry the balancer adjustments out For these operations refer to the balancer instruction manual For allowing an easier adjustment it is advisable to block the machine s vertical movement when carrying these adjustments out Longitudinal balancing Heavy arms Light arms Example with welder item 3323 With the welder complete with its arms one may carry the longitudinal balancing out by loosening the nut Y1 and by shifting the suspension arm on the guide as far as finding the point where the machine is balanced After the adjustment has been carried out carefully tighten the nut Y1
47. ent and complies with the laws in force Page 19 60 LORS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 5 WELDER SET UP 5 0 GENERAL NOTICE The reading of this chapter assumes to the purpose of a safe use of the welder the acknowledgement of what is stated in Chapter 1 Paragraph 4 General safety warnings Besides the specific prescriptions to safely operate the welder relating to this chapter are detailed in the following paragraphs 5 1 DESCRIPTION OF THE WELDING CONTROL UNIT The welder can be equipped with different types of control units either external to or built in the welder The following paragraphs describe the features of the different available types 5 1 1 BUILT IN CONTROL UNIT TE300 g RUN DELAY 8 PROG 1 oO 1 SQUEEZE 1 ACCOSTAGGIO SQUEEZE ACCOSTAGGIO PRE WELD TIME PRE SALDATURA CURRENT CORRENTE COLD TEMP FREDDO SLOPE SLOPE WELD TIME SALDATURA CURRENT CORRENTE WELD SALDA NO WELD NON SALDA START L INIZIO CICLO START 2 L INZIO CICLO 2 PRG 2 RECALL o o RICHIAMO PRG 2 L1 L1 AUX EN IMPULSES NUMBER AUSILIARIO NUMERO IMPULSI HOLD CORRENTE L V MANTENIMENTO SOLENDOID VALVE 1 EY OFF TIME ELETTROVALVOLA 1 INTERVALLO SOLENDOID VALVE 2 L NX ELETTROVALVOLA 2 MADE IN ITALY The function of the control unit is to manage the parts of the welders in particular the thyr
48. ess it is necessary to execute the following procedure before restart the production in order to restore the normal transformer magnetization condition carry out some welds with an insulator placed between the electrodes with different current adjustments first low ones then progressively higher remove the insulator between electrodes and execute some welds with a low current adjustment at this point the procedure ends and the normal functioning conditions are restored In case of any water leakage which could enter the welder immediately disconnect the electric supply In case of fire do not use water but proper fire extinguishers EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 5 8 SAFETY RULES OPERATOR QUALIFICATION NUMBER OF OPERATORS o SAFETY MEASURES WELDER STATUS oo 9 For a safe welder employ the installation must be carried out by specialized personnel following all the instructions stated on the INSTALLATION chapter The welder maintenance must be carefully carried out by following all the safety instructions stated on the MAINTENANCE chapter In particular notice that the electrodes maintenance must be carried out according to either one of the following conditions with the welder switched off with the emergency button pressed down i The welder should be operated by trained personnel only in any case users operating the welder must be aware of the possible
49. g device supplied with the machine accomplishes this task 3 Close and discharge the water from the welder cooling circuit 4 Loosen the screws M and slightly rotate the lower arm B 5 Remove the insulating protection D after having removed the screws 6 First loosen then remove the screws g remove the electrode holder C 7 Carefully clean the contact surfaces of both the stem and the new electrode holder 8 Check that the gasket i and the electrode venue are not damaged eventually replace them 9 Check that the tube bringing water to the electrode inside stops at 3 5 mm from the bottom of the electrode hole If necessary use a different cooling tube as per the following pictures 10 Spread a light veil of conductivity grease on the electrode holder contact surface 11 Fixthe new electrode holder with the screws g without forgetting the steel washers h Tighten with a pair of 12 13 Nm 12 Reassemble the protection D 13 Correctly place the arm B again and tighten the screws M with a pair of 24 26 Nm EDITION MAY 2007 Page 31 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 Replacement of the lower arm N ONO gt CO Stop the electrical supply at the main switch supplying the welder Close the pneumatic supply and discharge the remaining air The cutting device supplied with the machine accomplishes this task Close and discharge the water from the welder
50. he safety warnings stated in this manual nor it is responsible for damages coming from even slight tampering or from the use of not suitable spare parts or of spare parts other than the original ones 0 2 KEEPING OF THE INSTRUCTION MANUAL The instruction manual must be kept with care and must always follow the welder in all the changes of property that it could have during its life The good keeping must be enhanced by a careful handling with clean hands and having care not to put it on dirty surfaces It is forbidden to take off tear or to arbitrarily change parts of this instruction manual The manual must be stored in a place safe from humidity and heat and close to its relevant welder 0 3 HOW TO UPDATE THE INSTRUCTION MANUAL In case of any modification on the welder installed at the customer premises that have been agreed upon by the manufacturer and that require to change the Instruction Manual the manufacturer should send the revised Instruction Manual The user is responsible for changing the old manual with the new one Page 5 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 1 GENERAL INFORMATION 1 1 MANUFACTURER IDENTIFICATION DATA MANUFACTURER TECNA S p A HEADQUARTERS TECNA S p A Via Grieco 25 27 40024 Castel San Pietro Terme Bologna Italy PH 39 051 6954400 Fax 39 051 6954490 e mail sales tecna net vendite tecna net http www tecna net 1 2 IDENTIFICATI
51. idity varying from 15 to 9595 ALTITUDE The welder can work at a max 1000 m altitude without a lowering of performance ILLUMINATION The welder has been designed taking into account the prescriptions to make the operator work easily The lighting system of the plant is also important for the people safety EXPLOSIVE AND OR FLAMMABLE ATMOSPHERE The standard version of the welder is not designed to work in either explosive atmosphere or flammable ones EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 4 2 LOCATION OF THE WELDER The welder should be installed in a position having the following features Indoors the welder is not designed for working outdoors na well ventilated area free from dust steam and acid exhalations The working place must be free from inflammable materials because the working process can produce spatters of melted metal Around the welder there must be enough room to carry out both working and maintenance in a comfortable manner and without any risk In a place with a suitable lighting system in comparison with the work to be carried out The place of installation must be necessarily flat and the ground must be without unevenness which can be dangerous when working If the welder is used to carry out welding processes which can cause smoke exhalations a proper aspirator must be installed Page 16 60 LCRS TECNA 4 3 ACCOMPLISHMENT OF THE AS
52. ions to safely interact with the welder relevant to this chapter are detailed in the following paragraphs 3 1 PACKING THE WELDER CAN BE PACKED ON PALLET Then it is covered by a poly ethylene film to get a higher protection Protruding parts are usually disassembled and packed separately Upon receipt of the welder it is necessary to check visually with the lorry driver the complete integrity of the packing and inform any damage to a responsible Any damage on the packing should raise doubts about the integrity of the welder PACKING FEATURES PACKING DIMENSIONS See technical data table Values subject to change according to the configuration of the welder EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 3 2 TRASPORT AND HANDLING OF THE PACKED WELDER OPERATOR QUALIFICATION NUMBER OF OPERATORS o SAFETY MEASURES WELDER STATUS oo NOTICE The transport of the packed welder must be carried out by qualified personnel by means of an elevator or suitable lifting devices DESCRIPTION CONCERNING THE LIFTING BY ELEVATOR A Before starting any transport operation pay attention that the capacity of the elevator is suitable to the load to be lifted Position the forks in the correct position only Once the forks are positioned lift them slowly avoiding sharp movements Do not stop for any reason in the operation area and do not climb on the pallet while in movement 3 3 STORA
53. istor adjusting the welding current is a microprocessor welding control unit for resistance welding suspended spot guns This control unit includes specific functions to be used when working with suspended spot guns It is possible to set 2 different welding programs which can be recalled by an external device Each program is formed by 10 programmable parameters which describe the working cycle Besides the simple 4 times cycle the control unit enables to carry out welding processes with pre weld current and pulses Another available function of this control unit is the compensation of the minimum current MAIN TECHNICAL DATA Easy programming by 5 push buttons oynchronous thyristors drive device with phase shift control for welding current adjustment 2 welding programs to be stored up and selectable by an external device 10 programmable parameters for each program Slope pulses and pre weld functions oingle and automatic cycle Compensation of the secondary current to weld oxidized sheets and rods WELD NO WELD function Delay of first phase shift adjustment to get the best balance of the welder absorption from the mains Control of 2 solenoid valves 24 Vdc 7 2 W Max with protected output against short circuit electrode closing valve and double stroke valve For further information concerning see relevant instruction manual EDITION MAY 2007 Page 20 60 LORS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324
54. kes the welder stop if the cooling water does not circulate ACCESSORIES 3311 Removable key selector for programming lock for TE300 welding control unit 3312 Removable key selector for programming lock for TE450 welding control unit O 3313 Holder to mount the control handle on the lower side of the spot gun for items 3321 3322 3323 3324 O 3314 Holder to mount the control handle on the lower side of the spot gun for items 3327 3328 3315 Holder to mount the control handle on a spot gun side complete with another handle without control EDITION MAY 2007 Page 12 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 2 4 FORESEEN USE AIR OPERATED PRODUCTION SPOT WELDING GUNS WITH BUILT IN ELECTRONIC TIMER ANY USE DIFFERENT FROM AND NOT FORSEEN IN THIS MANUAL MAKES TECNA S p A RESPONSIBLE FOR ANY RISKS SHOULD TAKE PLACE In any case the use of materials different from the ones agreed upon the purchase EXCLUDES TECNA S p A FROM ANY RESPONSIBILITY FOR DAMAGES TO THE WELDER THINGS OR PEOPLE The electrical system is not foreseen to be used in anti explosion environments and for flammable products EDITION MAY 2007 Page 13 60 LCRS TECNA 3 TRANSPORT AND HANDLING 3 0 GENERAL INFORMATION The reading of this chapter assumes in order to safely use the welder the knowledge of what stated in Chapter 1 Paragraph 4 General Safety Warnings In addition the specific prescript
55. lifting conveyors A Pay attention before transporting the welder that the capacity of the elevator is suitable with the load to be lifted The welder must be handled only by means of its own suspension system Until the suspension arm is not mounted in the welder use the proper hole located on the suspension fixing plate Once the suspension arm has been installed use the same for handling the welder Take into consideration the welder weight as shown in the paragraph TECHNICAL FEATURES EDITION MAY 2007 Page 15 60 LCRS TECNA 4 INSTALLATION 4 0 GENERAL WARNINGS The reading of this chapter to the purpose of the safe use of the welder assumes the acknowledgement of the Chapter 1 Paragraph 2 General Safety Warnings These paragraphs are intended for specialized personnel responsible for the handling and installation of the welders Moreover the specific prescriptions for safely interact with the welder relating to this chapter are detailed in the following paragraphs 4 1 REQUIRED ENVIRONMENT CONDITIONS The machine is intended to work under the environmental conditions specified in the following points if not otherwise state in the order form TEMPERATURE The welder can work at a room temperature included between 0 and 40 FOR STOCKAGE ONLY if the water is removed from the water cooling circuit the welder can be stored up to 20 C HUMIDITY The welder can work at a hum
56. nected to the protection conductor that the ground wire inside the supply cable is not cut e Periodically check the ground efficiency EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 e Often check both the status and the proper functioning of the control devices and of the corresponding connecting cables e Frequently check the proper functioning of the earth leakage circuit breaker by means of the relevant test button e Frequently check the proper functioning of the earth leakage circuit breaker which must be installed on the supply mains and of the other eventual protection devices 8 2 EXTRAORDINARY MAINTENANCE OPERATOR QUALIFICATION NUMBER OF OPERATORS SAFETY MEASURES WELDER STATUS oO Q This chapter states the maintenance operations to be carried out in case of 1 lowering of the welder performances 2 welder wrong operating 3 welding faults 8 2 1 LOWERING OF THE WELDING UNIT A PERFORMANCES Extraordinary maintenance must be carried out by specialized personnel only equipped with the proper instruments and trained to accomplish it under safety conditions When possible the welder must be disconnected from both pneumatic and electric supply If the performances are lower than expected check e That when welding line voltage drop is lower than 1575 e That the supply cables section is adequate e That the electrodes diameter is appropriate for the work to be ca
57. odes Electrodes Welding current Welding time Obtained minimum overlapping force nugget a distance D min d max mm y 7 m d _5 9 2 L 6 24 6 Eg 6 10 4 E dr 5 10 10 78 mm 5 10 10 10 2 5 EE E EN L 9 LA LO 10 LM oj 19 1 18 for stainless steel with resistance up to 100 kg mm2 for stainless steel with resistance beyond 100 kg mm2 NN NN 860 aN 35 95 45 20 80 16 770 16 860 139 2 7 9 1 1 25 35 20 A 2 2 3 4 5 8 11 2 14 18 m 5 10 10 10 16 16 19 9 14 16 16 18 20 2 DISTANCE BETWEEN SPOTS OVERLAPPING Set down 30 N B In the welding of reinforced concrete rods there are cases in which the same parameters can be used to weld different much higher diameters y A 2 B moms BEFORE WELDING AFTER WELDING EDITION MAY 2007 Page 55 60 LORS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 10 3 TE300 PRODUCTION FORM FACSIMILE FIRM DATA WELDER DATA Welder Model Welding transformer connecting positions PIECE TO BE WELDED WELDING PARAMETER ADJUSTMENT WELDING CONTROL UNIT TE300 PARAMETERS No PARAMETER PROGRAMNo PROGRAMNo2 _ p 2 3 eewo Ca current 5 O o O
58. omer at his own exclusive risk and responsibility by using specialized personnel who should carefully follow the indications of this instruction manual Before connecting the welder to the mains supply check if the voltage shown on the features plate corresponds to the one of your mains supply When realizing the supply line of the welder consult the Technical features table to determine the cables section to be used These values are the minimum advised However they must be checked taking into consideration the installation conditions the typology of the materials being used and the laws in force in the installation place The welder is equipped with an earth leakage circuit breaker located at the end of the supply cable Besides breaking the electric supply this device has safety functions therefore it must not be absolutely taken off The switch must be installed close to the working place so that the operator can easily reach it If the breaking capacity offered by the earth leakage circuit breaker is not adequate to the mains system or if it is required by the laws in force install delayed fuses in the size shown in the Technical Features paragraph granting an adequate breaking capacity The paragraph TECHNICAL DATA 2 3 features of the supplied switch reports the The connection of the welder to the protection conductor earth conductor is compulsory Check that the conductor of the protection system is effici
59. on the pressure gauge are listed in the following tables EDITION MAY 2007 Page 43 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 255 695 6 5 10 26 45 60 Item 3327 dan 10 26 m Tom 255 695 7 45 60 408 386 10 12 65 75 820 196 18 130 175 4883 300 3 2 5 20 35 50 3 9 5 50 F Force at the electrodes at a 600 kP 6 bar By means of two flow regulators it is possible to adjust the electrodes opening V and closing Z speeds The adjustment is carried out by means of a screwdriver Xe mm AL AS aware that too slow electrodes clamping speed adjustment can cause either an insufficient force at electrodes at the welding start or a welding start occurring before the contact if the squeeze time is too slow EDITION MAY 2007 Page 44 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 7 4 WORKING PROGRAM ADJUSTMENT This operation enables to choose the welding parameters and to enter them directly on the welding control Select parameters from table or personal experience taking into consideration the plate thickness the welding desired quality etc We suggest using short welding times to reduce the electrodes heating thus increasing their life at the same time avoiding oxidation on the contact surfaces The best quality welds are obtained by using welding times as short as possible with high current and high electrode force Notice that
60. operations out 1 Stop the electrical supply at the main switch supplying the welder 2 Close the pneumatic supply and discharge the remaining air The cutting device supplied with the machine accomplishes this task Close and discharge the water from the welder cooling circuit Loosen the screws M Carry out the longitudinal adjustment of the arm Tighten the screws M with a pair of 24 26 Nm Carry out the arms parallelism adjustment by loosening the screw C and by placing between the electrodes a thickness equal to that which must be welded Tighten the screw C with a pair of 12 13 Nm A This type of operations must be carried out when the machine is on therefore one must operate using the maximum caution and carefulness Carry out some tests with the control unit on NO WELD mode using the same electrodes force employed to carry out the work place between electrodes a thickness equal to that which must be welded It is of the utmost importance that the arm is properly fitted into the arm holder A ED LL B LII l c O1 Co Do not tighten the screws M if the arm is not fitted EDITION MAY 2007 Page 37 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 7 2 4 ELECTRODES ADJUSTMENT OPERATOR QUALIFICATION NUMBER OF OPERATORS SAFETY MEASURES WELDER STATUS 1 oo i The electrodes replacement must be carried out so not to damage the el
61. ose of the water cooling circuit of the welder this is to avoid that deposits obstruct or redu ce the water cooling hoses causing damages to the welder In case of water cooling by closed circuit this softener should be positioned before the supply of the bath which contains the water used for cooling We recommend using water with a maximum hard water of 10 H French degrees 1 fH French degree corresponds to 0 56 dH German degree and to 0 7 eH English degree Check that the water being used is clean Suspended particles in the cooling liquid might sediment in the machine reducing or canceling the cooling capability and causing serious damages For this reason it is always advisable to assemble a proper filter on the machine supply Once the installation has been accomplished it is necessary to check that the water flow in the welder corresponds to the quantity shown in Technical Features paragraph EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 ELECTRICAL INSTALLATION OPERATOR QUALIFICATION NUMBER OF OPERATORS o SAFETY MEASURES WELDER STATUS oo A The welders in this manual have been designed exclusively for professional use in an industrial environment They must not be installed in low voltage public lines which supply domestic premises This can cause electromagnetic interferences The electrical installation of the welder to the mains supply is carried out by the cust
62. risks and must have both read and understood this manual 1 Only authorized personnel carry out the welder adjustment The welder adjustments affect the operative safety so much so that they must be carried out by qualified personnel only Carefully follow the instructions stated on the WORKING PROCESS chapter It is forbidden to have more people working on the welder at the same time No admittance allowed to the working area to people other than the operator Ey 1 WEM In case of water entering the welder immediately stop the electrical supply When operating heavy working high thickness and pieces with a difficult coupling wear safety shoes and aprons and use protection screens to protect the operator from possible spatters of melted materials Page 22 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 The safety shoes must be worn each time the pieces to be welded because of their shape or weight bear risks requiring them Keep the welders nearby working area free from flammable materials In case the material to be welded produces either smokes or exhalations install a proper aspirator The noise produced by the welder depends mainly on the adjustments To reduce the noise Adjust the working stroke to the minimum value allowing carrying out the operation e Adjust the working stroke to the minimum value allowing carrying the operation o
63. rried out e That cooling water circulates in the required quantity That the welding pressure shown by the pressure gauge is adequate for the work in process e That the pressure gauge works properly Page 47 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 8 2 2 REPAIR OR REPLACEMENT OF THE SUPPLY CABLE The supply cable is often subject to heavy mechanical stress which may cause damages The occurred damage may involve both the cable interruption and short circuit Remember that the cable interruption may also be limited to the protection conductor only For this reason it is of the utmost importance that some standard maintenance is carried on the cable out so to periodically check the continuity of the protection circuit Should the cable got damaged because of short circuit please remember that the earth leakage circuit breaker would immediately open In this case the switch may get damaged and it would therefore be necessary to replace it The cable maintenance may also be preventative should the machine stop over caused by this potential damage be too burdensome Carry the intervention out by opening the R1 connection box Dependently on the general wear status of the cable on the breaking point distance from the machine and on the availability of a cable sufficient length for carrying the repair out one may either integrally replace the cable or repair the same by shortening its length The necessary operations
64. s to be followed for carrying the arms replacement out are reported here below EDITION MAY 2007 Page 30 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 ARMS REPLACEMENT IN THE TYPE SUSPENDED WELDING GUNS ITEM 3323 The secondary surface increase causes a performances decrease Therefore it is always advisable to use those arms sets allowing the work to be done but having the smallest area Besides allowing obtaining better quality welds this adjustment enables improving the machine s handling When carrying the arms replacement out it is advisable to block the welder vertical movement by means of the balancer block control This prevents the machine from moving because of the weight change The improper use of the balancer block device may involve serious risks Refer to the balancer instruction manual Carefully read the balancer instruction manual and scrupulously follow its indications The arms sets and electrodes replacement must always be carried out while the water cutting valves P are closed and the machine front part faces downwards so to prevent the water from entering the welder In case of water entering the welder immediately stop the electrical supply and proceed with both loss and water removal Replacement of the movable electrode holder C Stop the electrical supply at the main switch supplying the welder 2 Close the pneumatic supply and discharge the remaining air The cuttin
65. sanitary rules in force are applied in the place where the welder will be installed The instructions drawings and the content of this manual have a technical nature and their property is strictly reserved to the manufacturer and cannot be reproduced in any way neither fully nor partially Besides the customer undertakes the responsibility to check that in case this document is modified by the manufacturer only the updated versions of this manual are present where the welder is used This welder has been designed for resistance welding of both ferrous and non ferrous aluminum brass materials The welder must not be used for other applications i e pieces heating mechanical working carried out by using the electrodes force The welder has been designed to be used by an operator by using the foreseen control devices All modifications even slight ones are forbidden because they should invalidate the welder CE certification EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 A The welders described in this manual have been designed to be used only for professional purposes in industrial environments They must not be installed on public lines at low voltage supplying domestic premises This can cause electromagnetic interferences TECNA S p A is not responsible for any damage to both people animals things and to the welder itself caused by a wrong use or the lack or the superficial observance of t
66. stence and provides the instructions and the advice for overcoming the same see respectively 5 5 and 5 5 1 of the European Regulations EN 292 1 e EN 292 2 SAFETY COMPONENT We mean a component used for ensuring a safety function Should it be either damaged or work improperly it would compromise either the safety and or the health of the exposed people for instance lifting tool fixed mobile adjustable protector etc electric electronic optical pneumatic hydraulic device interlocking a protector etc Page 7 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 ATTENTION SYMBOLS black on yellow background OMEN Do not wear watches ATTENTION The information enclosed in this paragraph OBLIGATION SYMBOLS white on light blue background e has the utmost importance Wear approved goggles Protections against noise Wear approved gloves Inflammable material Wear approved safety shoes Danger of explosions Specialized personnel only Danger of electric shock PROHIBITION SYMBOLS black on white background and prohibition in red Disconnect voltage The use is forbidden to wearers of pace makers This is valid both for the operator and for the people around the working area and the cables Do not bring near any kind of documents with magnetic Strips EDITION MAY 2007 Page 8 60 LCRS TECNA 2 INFORMATION ABOUT THE WELDER
67. t to this chapter are detailed in the following paragraphs 6 1 CALCULATION OF THE MAXIMUM WELDING RATING Before starting the production it is necessary to check that the welding rating does not exceed the maximum welding rating allowed by the welder in comparison with the set welding conditions time and current otherwise causing a too high over heating To carry out this test it is necessary to know the used welding current which must be measured with an adequate welding ammeter The control unit is equipped with an integrated ammeter TE450 TE510 The welder maximum welding rating is the function of the thermal load applied to the welder itself depending on both the used time and welding current and on the numbers of welds for unit of time With these different parameters it is possible to define the Ith value that is to say the equivalent thermal current at the duty cycle of 100 Its value is number of welding cycles per minute X welding current in 3000 The resulting value must be lower than the welder maximum one this value is stated the Technical Features paragraph Otherwise it is necessary to reduce the welding rate When different welding programs or when a welding cycle with pre heating or post heating are employed the value of these different currents must be calculated separately and then added in order to obtain the equivalent total value Example 1 Cycle simple Welding current 13000 A 18
68. te tete tete 23 55 tue MEL MM E M E MAT M LE M DEM EE E TAE 25 6 MACHINE USE 26 60 GENERAL INFORMATION retener tette k EEA LA AEEA tete ttt nnana 26 6 1 CALCULATION OF THE MAXIMUM WELDING 26 6 2 TROUBLESHOOT ING 27 6 3 REMEDIES FOR WELDS IMPERFECTIONS scssessecssesseceessessessecsucsucssecsesecseeseessuesussessussuesuesecsecseeseveee 29 7 INSTRUCTIONS FOR THE ADJUSTMENTS c csscescscsesecsessessesceesescucsssassaesstsstssessatsatsssessassatsateateaser 30 7 0 GENERAL INFORMATION cccccsessessesseessecsecsessecsessecsecsucsucssecscsucssessessussucsuessesacsetssesecsetssesssssuessessesseseeaseen 30 7 1 STANDARD ACCESSORIES ttt ttt 30 7 2 MECHANICAL SET UP ccscscescscseecsessessecssessesscsucesecscseecsessessucsussussuesacsecssesseseessessussussusssessesstsstsssestesseseesees 30 7 2 1 ARMS SELECTION AND REPLACEMENT 30 7 2 2 SUSPENSION ADJUSTMENT tette 34 7 2 3 ARMS ADJUSTMENT k annn te teneat Ga Run Gebet teste te 36 7 2 4 ELECTRODES ADJUSTMENT c ccsssscceccecceccecsecssesseccecsecsecsecseesecseesaesaessucsucsecsersacsatsatssecsecsussetsaessecsecsecen 38 7 2 5 WORKING STROKE ADJUSTMENT ett ttes Dd 40 EDITION MAY 2007 Page 2 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 T20 DOUBLE STROKE USE iae io dEEEGTIBODEFOBRGCEJA
69. tections and safety devices which have been deemed necessary and finally it is provided with information enough for its safe and correct use To this purpose in each chapter when necessary for the operator welder interaction the following information have been provided Minimum operator skills required Number of operators required Status of the welder Remaining dangers Necessary or suggested protection devices Avoidance of human errors Prohibitions obligations referred to mistaken actions which can be reasonably foreseen A This information should be carefully followed Page 6 60 LCRS TECNA The user can appropriately add information to the ones provided by the manufacturer for example additional working instructions which of course must not be in contrast to what is stated in this manual in order to help safe use of the welder For example particular attention must be paid to the clothes worn by anyone working with the welder avoid wearing clothes with holds which could be caught into the welder avoid using ties or flying clothes avoid wearing large rings or armlets which could get the hands caught by the welder When necessary this manual will specify further recommendations for the user about the preventive measures personal protection devices information aimed to prevent human errors and prohibitions for wrong behaviors which can be reasonably foreseen In any case it is necessary to caref
70. the support it is necessary to adjust its capacity It is recommended to leave a slight tendency to slope up in order to get better results Once the balancing has been accomplished check that all the rope of the balancer can fully exit so that the spring is not too much pre loaded to limit the stroke Once the assembly of the suspension system has been accomplished it is necessary to carry out the balancing adjustments see SUSPENSION ADJUSTMENT paragraph Models 3327 3328 per 7 2 L y LEEHG T c r Pal CC Bearing C Bushing C Bushing E Suspension washer F Suspension screw G Suspension arm Y1 Pin Y2 Headless screw Page 17 60 LCRS TECNA 4 4 CONNECTION TO THE ELECTRIC SUPPLY PNEUMATIC CONNECTION OPERATOR QUALIFICATION NUMBER OF OPERATORS o A SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 SAFETY MEASURES WELDER STATUS oo Before performing any connection to the system of the plant check the perfect cleaning of the hoses they should be free from any external dust remaining from the unpacking or from storage in an inconvenient place For a proper connection of the welder to the compressed air supply it is necessary to have a centralized plant or a compressor able to produce dry and cool air within the maximum pressure limit and in the quantities shown in the Technical Features par
71. ully follow the indications here below e Itis absolutely forbidden to void the safety devices installed in the machine The operations at a reduced safety rate must be performed by carefully following the instructions provided in the relevant descriptions e After an operation at a reduced safety rate the normal status of the welder must be restored at the soonest The cleaning operations must be performed with electrical and pneumatic devices switched off Do not modify parts of the welder for any reason in case of malfunctioning due to this reason the manufacturer is not responsible It is advisable to ask for any modifications directly to the manufacturer Clean the covers of the welder the panels and the controls with dry soft clothes or slightly wet with a soft cleaning solution do not use solvents like alcohol or gasoline resulting in a possible damage of the welder e Place the welder as established upon order if not the manufacturer is not responsible for any inconvenience EDITION MAY 2007 SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 1 5 GLOSSARY AND SYMBOLS ON THE WELDER AND IN THE MANUAL This paragraph lists the words which are not commonly used or which are used with a meaning different from the common one This paragraph also explains the short forms used in the manual and the meaning of the symbols used to show the operator skill degree and the status of the welder their use enables
72. ut e Work having the double stroke activated e Adjust both the electrodes opening and closing speeds to low values Periodically check the silencers Should the noise produced by the welder during the working phases exceed the safety threshold wear the proper protection headphones In addition to the information stated on this chapter always operate in accordance with all the relevant laws in force 5 4 MACHINE FUNCTIONING OPERATOR QUALIFICATION NUMBER OF OPERATORS OPERATOR 1 SAFETY MEASURES WELDER STATUS The welder was designed for being used by an operator placed as represented in the pictured examples EDITION MAY 2007 Page 23 60 LCRS TECNA When arranging the working place always follow the instructions mentioned below Usea well ventilated area free from dust steam and acid exhalations The working place must be free from inflammable materials because the working can produce sparks and projections of melted metal Around the welder there must be enough room to carry out both working and maintenance in a comfortable manner and without any risk e fthe welder is used to carry out welding processes which can cause smoke exhalations there must be installed a proper aspirator Before starting the working process following adjustments carry out the 1 Mechanical set up 2 Electrode force adjustment 3 Welding parameters adjustment 4 Calculation of the maximum welding
73. x 10 x 13000 Welding time 18 periods D 3000 184A 10 welds per minute Example 2 Cycle with pre weld 3 Welding current 20000 A 12 x 6 x 20000 Welding time 12 periods Int Wo 2 3098A 3000 8 Pre weld current 9000 A Pre weld time 4 periods 4 x 6 x 9000 22 05A 6 welds per minute i 3000 Rd 3098 805 3200 Example 3 Cycle with pre weld and post weld 2 welds per minute 18 x 2 x 18000 Welding current 18000 A Ip 1972 Welding time 18 periods 6 welds per minute 12 x 6 x 9000 Welding current 9000 A ew 1394A Welding time 12 periods bor ug 1972 1394 2415A NOTE Above formulas are for 50Hz supply lines For 60Hz supply lines change the 3000 value with 3600 EDITION MAY 2007 Page 26 60 LCRS TECNA SUSPENDED SPOT GUNS 3321 3322 3323 3324 3327 3328 6 2 TROUBLESHOOTING Troubleshooting must be carried out by specialized personnel only equipped with the proper instruments trained to accomplish it under safety conditions When possible disconnect both electric and pneumatic supply Shouldn t the welder work properly use the following table to identify the trouble and find the proper remedy FAULT CAUSE REMEDY The control unit does not switch Either connectors or cables Check on disconnected Control unit led ON keeps The fuses FU1 FU2 placed insi

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